Multi-seamed self-contained personal warming apparatus and method of warming

ABSTRACT

Self-contained disposable single-use heat generating apparatuses and methods for providing heat are disclosed. One exemplary apparatus includes a heat generating pack having a first bag layer defined by a first surface area bonded to a second bag layer defined by a second surface area and creating multiple pouches therebetween. A heat generating agent is disposed within the pouches and adapted to consume air at a predetermined consumption rate in an exothermic reaction. At least a portion of one of the first surface area and the second surface area comprises an air permeable surface area having a predetermined airflow rate such that the heat generating agent remains substantially evenly distributed within the pouches.

CLAIM OF PRIORITY

This is a continuation-in-part of application Ser. No. 10/405,668, filedApr. 1, 2003, entitled “Self-Contained Personal Warming Apparatus andMethod of Warming,” to which this application claims priority. Thisapplication is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention is generally related to warming devices and, moreparticularly, is related to a self-contained personal warming apparatusand method of warming.

BACKGROUND

Heat generating pouches of various configurations and shapes aredesigned and used for various purposes, such as hand warming, feetwarming, and the like, by placing the heat generating pouch in a glove,mitten, shoe, etc. Heat generating pouches typically comprise a heatgenerating compound disposed between at least two layers of material,such as fabric, or the like, assembled to form a pouch. The heatgenerating compound emits heat during an exothermic chemical reactionresulting from exposure of the compound to air. Known heat generatingcompounds typically comprises a loose granular substance that is freelymovable within the pouch. With a freely movable compound, when the pouchis placed flat, or horizontally, the compound is somewhat evenlydistributed throughout the pouch. However, when the pouch is placedvertically, moved around, or jostled, the compound is drawn by gravity,shifts and settles toward one end of the pouch. This shifting andsettling of the compound is sometimes referred to as a “tea-bag” effect.The tea-bag effect results in an uneven temperature profile along thesurface area of the pouch. An uneven temperature profile can result insome areas not receiving heat, as desired, or an over concentration ofheat in other areas.

The problem of the compound tending to shift and settle within the pouchhas been addressed by other configurations of heat generating pouches.In one embodiment, the heat generating compound is contained withinpucks or pellets that are disposed between at least two layers ofmaterial. The pucks or pellets comprise a heat generating compoundcapable of reacting with air in an exothermic reaction. The compound iscompressed into concentrated, substantially rigid, pellets. In thisconfiguration, however, the heat emission is concentrated at the pucks,resulting in an uneven heat distribution across the surface area of thepouch. Furthermore, because the pucks are rigid, the pucks do notconform to various contours of the human body against which the heatgenerating pouch may be placed.

The undesirable effect of a shifting compound has also been addressed byintroducing air to the heat generating compound through only one of thetwo layers of material forming the pouch, while the other of the twolayers of material comprises a self-adhesive. However, these adhesivepouches can not be easily inserted into pockets formed in socks, gloves,mittens, specially designed belts, or the like for use. Indeed, suchadhesive pouches are typically fixed to an interior surface of a user'sclothing. In this configuration of use, the pouch moves away from theuser's skin as the clothing moves away from the user's skin.Furthermore, fixing the pouch to a user's clothing typically results inminimal or no pressure being applied to the pouch as the pouch isapplied to the user's skin, thereby rendering the pouch less effective.

Thus, a heretofore unaddressed need exists in the industry to addressthe aforementioned deficiencies and inadequacies.

SUMMARY

One embodiment of the present invention provide a self-containeddisposable single-use heat generating apparatus and methods of providingtherapeutic heat. Briefly described, in architecture, one embodiment ofthe apparatus can be implemented as follows. A self-contained disposablesingle-use heat generating apparatus includes a heat generating packhaving a first bag layer bonded to a second bag layer creating aplurality of pouches therebetween. A heat generating agent is disposedin the pouch. At least a portion of one of the first bag layer and thesecond bag layer has an air permeable surface area with a predeterminedairflow rate. The airflow rate through the air permeable surface area ispredetermined such that the heat generating agent remains substantiallyevenly distributed within the pouches.

Other embodiments of the present invention can also be viewed as amethod for providing therapeutic heat, including forming and/or usingthe heat generating apparatus. In this regard, one embodiment of such amethod, among others, can be broadly summarized by the following steps:containing a heat generating composition in a plurality of pouches in aself-contained heat generating pack and introducing air to the heatgenerating composition, such that the heat generating compositionremains substantially evenly distributed within the heat generatingpack.

Other systems, methods, features, and advantages of the presentdisclosure will be or become apparent to one with skill in the art uponexamination of the following drawings and detailed description. It isintended that all such additional systems, methods, features, andadvantages be included within this description, be within the scope ofthe present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the invention can be better understood with reference tothe following drawings. The components in the drawings are notnecessarily to scale, emphasis instead being placed upon clearlyillustrating the principles of the present invention. Moreover, in thedrawings, like reference numerals designate corresponding partsthroughout the several views.

FIG. 1 is a cutaway perspective view of an embodiment of theself-contained personal warming apparatus of the present invention.

FIG. 1A is a perspective view of an embodiment of a self-containedpersonal warming apparatus illustrated in FIG. 1.

FIG. 2 is a plan view of an embodiment of a bag layer of the apparatusillustrated in FIG. 1.

FIG. 3 is a plan view of an embodiment of a bag layer of the apparatusillustrated in FIG. 1.

FIG. 4 is a plan view of an embodiment of a bag layer of the apparatusillustrated in FIG. 1.

FIG. 5 is a plan view of an embodiment of the disclosed self-containedpersonal warming apparatus.

FIG. 6 is a plan view of an embodiment of the disclosed self-containedpersonal warming apparatus.

FIG. 7 is a plan view of an embodiment of the disclosed self-containedpersonal warming apparatus.

DETAILED DESCRIPTION

FIG. 1 illustrates one preferred embodiment of a self-containeddisposable single-use heat generating apparatus 10 of the presentinvention. A heat generating pack 111 comprises a first bag layer 12, asecond bag layer 14 and a heat generating agent 16 disposedtherebetween. The first bag layer 12 is defined by a first set ofdimensions and has a first surface area. The second bag layer 14 isdefined by a second set of dimensions and has a second surface area. Itshould be noted that although the dimensions of the first bag layer 12and the second bag layer 14 are illustrated as being substantiallyrectangular in shape, the dimensions can form any suitable shape. Thefirst surface area can substantially correspond to the second surfacearea.

The first bag layer 12 and the second bag layer 14 are aligned, one ontop of the other, and are fixed together by at least one seam 18. Theseam 18 can either extend around the perimeter of the heat generatingpack 111 where the first bag layer 12 and second bag layer 14 meet, orrun along one or a plurality of edges thereof. As illustrated in FIG. 1,the seam 18 runs along two opposing edges. The seam 18 is created in anysuitable manner, for example by melting, bonding, or sewing.

At least one enclosed space, or pouch 20, is created between the firstbag layer 12 and the second bag layer 14. Although only one enclosedspace 20 is shown in FIG. 1, as discussed later, multiple pouches 20 canbe formed in the heat generating pack 11. At least a portion of one ofthe first surface area and/or the second surface area is/are preferablyair permeable as discussed in greater detail below. The first bag layer12 and the second bag layer 14 preferably comprise a flexible fabric,material, or the like.

A heat generating agent 16 is disposed within the pouch 20 and containedtherein. The heat generating agent 16 comprises a main ingredient ofiron powder and incorporates therein water, a water retaining material(charcoal, vermiculite, or the like), an oxidation promoter, such asactivated carbon, and salt. More particularly, and as an example, theagent 16 may comprise approximately 35-50% by weight of iron powder,25-45% by weight of water, approximately 10-14% by weight of waterretaining agent, and approximately 4.5-6% by weight of salt. Uponexposure to air, oxidation of the iron begins in an exothermic reaction.The heat generated by the exothermic reaction of the agent 16 passesthrough the first bag layer 12 and the second bag layer 14 and radiatesfrom the apparatus 10. It is preferable that the heat radiating from theapparatus 10 ranges from 39-45° C. in order to provide a level of heatsuitable for therapeutic heating without danger of burn to human skin.

During the exothermic reaction, the heat generating agent 16 consumesair at a predetermined air consumption rate. Controlling the rate ofintroduction of air to the heat generating agent 16 effects both thetemperature radiated from the pack 11 as well as the shifting of theagent 16 within the pouch 20. Generally, the more air introduced to theheat generating agent 16, the hotter the pack 11 will become. Also,where the heat generating agent 16 consumes air faster than air isintroduced to thereto, a vacuum will be created.

More specifically, and with reference to FIG. 1A, an embodiment of theself-contained disposable single-use heat generating apparatus 10 isillustrated. In this embodiment, the heat generating pack 11 is disposedinside a protective package 22. The protective package 22 can behermetically sealed with the heat generating pack 11 inside such that noair or minimal air is introduced to the heat generating pack 11. In thisembodiment, the protective package 22 effectively eliminates theintroduction of air to the agent 16 thereby substantially preventing theheat generating exothermic reaction. The heat generating pack 11 isdisposed within the protective package 22 preferably at, or closelyafter, the time of manufacture, and the heat generating apparatus 10 canbe marketed, sold and stored in this configuration.

Referring next to FIGS. 2-4, various embodiments of bag layers 13, 15and 17 are illustrated. The bag layers 13, 15 and 17 can comprise thefirst bag layer 12, the second bag layer 14 or any suitable combinationthereof in order to form a heat generating pack 11. For example, a heatgenerating pack 11 can comprise a first bag layer 12 arranged in theconfiguration of bag layer 13 (FIG. 2) and a second bag layer 14arranged in the configuration of bag layer 17 (FIG. 4).

Selection of the configuration of first bag layer 12 and second baglayer 14 is driven by a desired airflow rate for introduction of air tothe heat generating agent 16. An air consumption rate of the heatgenerating agent 16 being at least slightly greater than an airflowintroduction rate to the agent 16 generates at least a slight vacuuminside the pouch 20. The vacuum created inside the pouch 20 reducesshifting and settling of the heat generating agent 16, or “tea-bagging,”within the pouch 20.

The substantially stationary disposition of the heat generating agent 16inside the pouch 20 results in a heat generating pack 11 that maintainsa substantially constant thickness. A substantially even heat profile isemitted across the surface area of the first bag layer 12 and the secondbag layer 14. The airflow rate through the combined first surface areaand second surface area of the first bag layer 12 and second bag layer14 preferably is less than the predetermined air consumption rate of theheat generating agent 16 during exothermic reaction. For example, a heatgenerating pack 11 having porosity allowing an airflow rate of 20,000sec./100 cc of air preferably contains a heat generating agent 16 havingan air consumption rate greater than 20,000 sec./100 cc of air duringthe exothermic reaction.

Referring more specifically to FIG. 2, one bag layer 13 configurationcomprises an air permeable surface area 24. The air permeable surfacearea 24 preferably comprises a microporous fabric. A preferredmicroporous fabric can comprise a nonwoven fabric formed from individualfibers that are pressed together forming an interlocking web of fibers.The fibers can be fixed to each other either mechanically (for example,by tangling the fibers together) or chemically (for example, by gluing,bonding, or melting the fibers together). The present invention cancomprise a microporous fabric known to one having ordinary skill in theart.

FIG. 3 illustrates a bag layer 15 configuration having a portion of thesurface area thereof comprising an air permeable surface area 24 and aportion of the surface area comprising an air impermeable surface area26. The air permeable surface area 24 preferably comprises a microporousfabric. A preferred microporous fabric for this configuration cancomprise a nonwoven fabric formed from individual fibers that arepressed together forming an interlocking web of fibers. The fibers canbe fixed to each other either mechanically (for example, by tangling thefibers together) or chemically (for example, by gluing, bonding, ormelting the fibers together). This configuration can comprise amicroporous fabric known to one having ordinary skill in the art. Theair impermeable surface area 26 of the bag layer 15 can comprisepolyethelene, polypropylene, or any suitable material. It is preferablethat the air impermeable surface area 26 exhibits a low coefficient offriction, such as to allow the heat generating pack 11 to easily slideinto a pocket (not shown) formed in a glove, sock, belt for holding heatgenerating packs in position, or the like. The preferred combination ofair permeable surface area 24 and air impermeable surface area 26 of thebag layer 15 of FIG. 3 is determined by the desired air flowintroduction rate to the heat generating agent 16 inside a pouch 11 thisbag layer 15 configuration may be used to form.

FIG. 4 illustrates another bag layer 17 configuration. The bag layer 17comprises an air impermeable surface area 26, such as polyethelene, orany suitable material. It is preferable that the air impermeable surfacearea 26 exhibits a low coefficient of friction, such as to allow theheat generating pack 11 to easily slide into a pocket (not shown) formedin a glove, sock, belt for holding heat generating packs in position, orthe like.

Applying the above disclosed bag layer configurations 13, 15 and 17,heat generating packs 11 of various configurations can be formed. Oneconfiguration of a heat generating pack 11 comprises a first bag layer12 comprising bag layer 13 configuration having an air permeable surfacearea 24 (illustrated in FIG. 2) and a second bag layer 14 comprising baglayer 17 having an air impermeable surface area 26 (illustrated in FIG.4). In this configuration the rate at which air is introduced to theheat generating agent 16 is controlled by allowing a pre-determined flowrate through the first bag layer 12 and allowing substantially no airflow through the second bag layer 14.

Another configuration of a heat generating pack 11 comprises a first baglayer 12 comprising bag layer 13 having an air permeable surface area 24(illustrated in FIG. 2) and a second bag layer 14 also comprising baglayer 13 also having an air permeable surface area 24 (illustrated inFIG. 2). In this configuration the rate at which air is introduced tothe heat generating agent 16 is controlled by allowing a pre-determinedflow rate through both the first bag layer 12 and the second bag layer14.

A heat generating pack 11 of the present invention can also comprise afirst bag layer 12 comprising bag layer 13 having an air permeablesurface area 24 (illustrated in FIG. 2) and a second bag layer 14comprising bag layer 15 having a portion of the surface area being airpermeable 24 and a portion of the surface area being air impermeable 26(illustrated in FIG. 3). In this configuration the rate at which air isintroduced to the heat generating agent 16 is controlled by the totalair permeable surface area 24 of the first bag layer 12 and the secondbag layer 14 combined. It is preferable that the airflow rate throughthe total air permeable surface area 24 of the first bag layer 12 andthe second bag layer 14 combined is less than the air consumption rateof the heat generating agent 16 during exothermic reaction.

A heat generating pack 11 of the present invention can also comprise afirst bag layer 12 comprising bag layer 17 having an air impermeablesurface area 26 (illustrated in FIG. 4) and a second bag layer 14comprising bag layer 15 having a portion of the surface area being airpermeable 24 and a portion of the surface area being air impermeable 26(illustrated in FIG. 3). In this configuration the rate at which air isintroduced to the heat generating agent 16 is controlled by the totalair permeable surface area 24 of the second bag layer 14. It ispreferable that the airflow rate through the total air permeable surfacearea 24 of the second bag layer 14 combined is less than the airconsumption rate of the heat generating agent 16 during exothermicreaction.

It should be noted that the above described heat generating packs 11 aremere examples and that any configuration combining air permeable surfacearea 24 with air impermeable surface area 26 is within the spirit of thepresent invention.

In one method of use of an embodiment of a self-contained disposablesingle-use heat generating apparatus 10 of the present invention, a heatgenerating pack 11 is disposed in a protective package 22 to eliminate,or at least minimize, introduction of air to the heat generating agent16 disposed inside the pack 11. The heat generating pack 11 is removedfrom the protective package 22. Air is introduced to a heat generatingagent 16 disposed within a pouch 20 of the heat generating pack 11. Thepouch 20 is formed by a first bag layer 12 and a second bag layer 14being peripherally bonded to each other. The heat generating pack 11 isagitated, such as by shaking or crumpling the pack 11 in order to beginor speed up an exothermic reaction of the heat generating agent 16 withair. The heat generating agent 16 consumes air in a heat generatingexothermic reaction, thereby emitting heat from the heat generating pack11. At least one of the first bag layer 12 and the second bag layer 14,or a combination thereof, allow air to be introduced to the heatgenerating agent 16. The introduction of air is preferably at a flowrate less than the air consumption rate of the heat generating agent 16during the exothermic reaction. The heat generating pack 11 can bepositioned, as desired.

In one method of use, the heat generating pack 11 can be inserted into apocket, for example a pocket disposed in a belt for heat applicationnear a user's skin on their back, stomach, or any desired location. Theheat generating pack 11 can also be inserted into a pocket formed in asock or glove for a user to warm toes and fingers, respectively. Theexothermic reaction of the heat generating agent 16 when introduced toair produces a heat emission ranging between 39-45° C. for approximately12 to 18 hours. Upon the conclusion of the exothermic reaction and thecooling down of the heat generating pack 11, the heat generating pack 11can be removed from the position at which it was placed for use anddisposed.

As noted above and demonstrated in FIG. 5, multiple pouches 20 can beformed in the heat generating pack 11. In one exemplary configuration,the first bag layer 12 and the second bag layer 14 are fixed together orjoined at multiple seams, such as seams 18, 19 shown in FIG. 5. In onesuch embodiment, the seams 18, 19 compartmentalize the heat generatingpack 11 into separate heat generating pouches 20. In the embodimentdepicted, the first seam 18 extends around the perimeter of the heatgenerating pack 11. The second seam 19 extends between two separatepouches 20. The first seam 18 and 19 can be formed in the same or adifferent manner. For example, one seam 18 can be formed first, followedby the formation of the second seam 19. Alternatively, both seams 18, 19can be created by, for example, melting both seams at the same time.Even though one particular configuration has been shown in FIG. 5 forthe seams 18, 19, one can envision other embodiments of a multi-seamedpack 11, for example in a criss-cross shape (as illustrated in FIG. 6),or multiple vertical and/or horizontal seams.

Alternatively, multiple pouches 20 can be formed from the first baglayer 12 and the second bag layer 14 as shown in FIG. 7. The pouches 20can be smaller in size and can be formed more as pockets in the heatgenerating pack 11. In this manner, areas 30 are formed in the pack 11whereby the first bag layer 12 and the second bag layer 14 are touchingin some manner to prevent shifting of the heat generating agent from onepouch 20 to another. The pouches 20 illustrated in FIG. 7 can be formedby discrete seams around each pouch, or by generally melting or bondingthe first bag layer 12 to the second bag layer 14 to bonded areas 30.

In one embodiment of the disclosed heat generating apparatus 10, thepouches 20 can include one or more scented compositions. As the heatgenerating agent 16 emits heat, the scented substances in the pouches 20will emit a stronger fragrance with the heat. The scent can be, forexample, but not limited to one or more of the following: fruits,flowers, spices, or combinations thereof.

It should be emphasized that the above-described embodiments of thepresent disclosure are merely possible examples of implementations, andare merely set forth for a clear understanding of the principles herein.Many variations and modifications may be made to the above-describedembodiment(s) without departing substantially from the spirit andprinciples of the disclosure. All such modifications and variations areintended to be included herein within the scope of this disclosure andprotected by the following claims.

1. A self-contained, disposable, single-use heat generating apparatus,comprising: a heat generating pack comprising: a first bag layer havinga first surface area; a second bag layer having a second surface area,said second bag layer being fixed to said first bag layer, such thatsaid first bag layer and said second bag layer defining a plurality ofpouches therebetween; a heat generating agent disposed in the pouches,said heat generating agent arranged and configured to consume air at apredetermined air consumption rate in an exothermic reaction; and atleast one of said first surface area and said second surface areacomprises an air permeable surface area having a predetermined airflowrate at which air is introduced to said heat generating agent, saidpredetermined airflow rate being arranged and configured to be less thansaid predetermined air consumption rate such that said heat generatingagent remains substantially evenly distributed within said pouch.
 2. Theapparatus of claim 1, wherein said first bag layer is defined by a setof dimensions substantially corresponding to a set of dimensionsdefining said second bag layer.
 3. The apparatus of claim 1, wherein atleast one of said first bag layer and said second bag layer comprises amicroporous material.
 4. The apparatus of claim 3, wherein saidmicroporous material comprises a fabric having a plurality of fibersforming an inter-locking web, wherein at least a portion of saidplurality of fibers are bonded to each other.
 5. The apparatus of claim1, wherein one of said first surface area and said second surface areacomprises an air permeable surface area and the other of said firstsurface area and said second surface area comprises an air permeablesurface area.
 6. The apparatus of claim 1, wherein one of said firstsurface area and said second surface area comprises an air permeablesurface area and the other of said first surface area and said secondsurface area comprises an air impermeable surface area.
 7. The apparatusof claim 6, wherein said air impermeable surface area comprises a lowcoefficient of friction.
 8. The apparatus of claim 1, furthercomprising: a protective package for receiving said heat generatingpack, said protective package being air impermeable and retarding saidexothermic reaction.
 9. The apparatus of claim 8, wherein saidprotective package is hermetically sealed with said heat generating packdisposed therein.
 10. The apparatus of claim 1, wherein the pouches areformed from seams in the heat generating pack.
 11. The apparatus ofclaim 1, wherein the heat generating agent disposed in each of thepouches is free-flowing prior to its consumption of air.
 12. Theapparatus of claim 1, wherein the plurality of heat generating pouchescomprise a substantially constant thickness, whereby a substantiallyeven heat profile is emitted across the surface area of the first baglayer and the second bag layer.
 13. The apparatus of claim 1, whereinthe pouches are formed from pockets in the heat generating pack.
 14. Theapparatus of claim 1, wherein at least one of the plurality of pouchesincludes a scented substance.
 15. A method for providing therapeuticheat, comprising the steps of: containing a heat generating compositionin a plurality of pouches in a self-contained heat generating pack, thecomposition having a predetermined air consumption rate; introducing airto said heat generating composition at a predetermined airflow ratearranged and configured to be less than said air consumption rate suchthat said heat generating composition remains substantially evenlydistributed within said heat generating pack; and providing a lowcoefficient of friction.
 16. The method of claim 15, further comprisingthe step of removing said self-contained heat generating pack from anair impermeable protective package.
 17. The method of claim 15, furthercomprising forming the pouches in the heat generating pack by formingseams in the heat generating pack.
 18. The method of claim 15, furthercomprising forming the pouches in the heat generating pack by formingseams in the heat generating pack, wherein the seams are formed bymelting together two layers of material of the heat generating pack. 19.The method of claim 15, further comprising forming the pouches in theheat generating pack by forming seams in the heat generating pack,wherein the seams are formed by bonding two layers of material of theheat generating pack.
 20. The method of claim 15, further comprisingforming the pouches in the heat generating pack by forming seams in theheat generating pack, wherein the seams are formed by sewing togethertwo layers of material of the heat generating pack.